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Engineers must understand how the components in the HVAC systems they design use
power and how they can be optimized without compromising traditional design values.
Motors and drives are shown in relation to the design of HVAC systems.
By: By John Yoon, PE, LEED AP, McGuire Engineers Inc., Chicago
Learning objectives:
Demonstrate how the energy codes directly affect motor and drive design.
Compare 6-, 12-, 18-pulse, and active front-end variable frequency drive (VFD)
technologies.
Understand how VFD selection impacts power quality.
Apply products and systems within HVAC design to improve energy efficiency.
Although variable frequency drives (VFDs) have been used in HVAC applications for a long time, the focus
hasn't extended much beyond basic functional and budgetary concerns. It is generally understood that using a
VFD can allow for significant energy savings through the affinity laws. It is also understood that with certain
types of fan systems like variable air volume (VAV) systems, VFD use is more or less required. However,
ongoing changes in applicable codes and standards have effectively eliminated many other HVAC design
options and made the use of VFDs a de facto requirement in many situations.
Code evolution
It should come as no surprise that major federal energy legislation (Energy Policy and Conservation Act of
1975, Energy Policy Act of 1992, Energy Independence and Security Act [EISA] of 2007) immediately
followed major global events that impacted the cost of energy. That same energy legislation directly resulted
in the energy codes and standards that affect our designs. Although projections from the U.S. Energy
Information Administration would seem to indicate that the long-term trend is for economic growth to decouple
from energy usage, the basic relationship should remain valid through 2040.
So, what exactly is the goal of energy codes and standards? The U.S. Department of Energy (DOE) is
responsible for national energy policy and has federal statutory authority for the evaluation of energy codes
and standards. They are given this authority through energy codes' ability to affect public health and welfare.
Energy codes and standards help ensure the public health and welfare by:
Reducing dependence on foreign energy by increasing efficiency and promoting alternate sources of energy
Protecting consumers through adoption of consistent standards
Providing for a more reliable electrical utility gird
Promoting economic development.
Efficiency in motors and VFDs is a prime target for any energy code or standard. The International Energy
Agency (IEA) estimates that electric motor-driven systems account for 43% to 46% of global electricity
consumption (7,108 terrawatt-hours [TWh]/year). Most of this is in the industrial sector. However, commercial
building usage still accounts for 1,412 TWh/year.
These are incredibly big numbers and it can be difficult to truly grasp their magnitude—1 TWh is equal to 1
billion kWh. So, while an increase of a few percentage points in efficiency for an individual motor may not
seem significant, it should be clear that small changes in industrywide motor-system efficiency standards can
dramatically impact global energy consumption.
Delay in adoption of
codes
While new energy-code requirements may seem overwhelming, what many specifying engineers don't realize
is that HVAC equipment manufacturers have been coping with these same problems for a longer period of
time. The changes in the minimum federal efficiency standards that are referenced in the energy codes
generally take place well in advance of their incorporation into those codes. For example, let's look at the
timeline for general-purpose squirrel-cage induction motors that are governed by the NEMA MG 1 industry
standard:
EISA 2007 mandates NEMA Premium efficiency levels for motors. Before this, there were both minimum
standard-efficiency and premium-efficiency offerings.
NEMA MG 1-2009 incorporates these as new minimum efficiency levels. MG 1-2009 became effective Dec.
19, 2010.
ASHRAE Standard 90.1-2013 and International Energy Conservation Code (IECC) 2015 incorporates these
MG 1-2009 requirements.
DOE gets up to 12 months to determine if these energy codes would effectively improve energy efficiency.
Each state is required to certify within 2 years that their commercial energy code is in compliance with the new
code.
All new motors currently in the marketplace should meet the minimum efficiency standards in MG 1-2009,
but most states, as of December 2015, still haven't adopted either ASHRAE 90.1-2013 or IECC 2015, which
mandate their use in new construction.
Motors are present in almost every piece of HVAC equipment that we specify and drive their overall energy
usage. However, barring unforeseen technological innovations, continuing increases in NEMA MG 1 efficiency
requirements are not sustainable. Motors are commodity products, and recent increases in efficiency can be
attributed to adopting previously "premium" product requirements and making those the base-level standard.
With each increase in motor efficiency, the associated manufacturing cost increases and, at some point, the
improved efficiency no longer justifies the additional costs.
Given the diminishing returns associated with further increasing motor efficiency, the next obvious target is to
focus how those motors are integrated and controlled within systems. With most HVAC systems, the peak-
load/design-day condition represents a small percentage of the overall operating hours for that system. When
considered in conjunction with the affinity laws, being able to operate motors at reduced speed/horsepower to
meet actual load requirements clearly has the potential for dramatic energy savings.
It is interesting to note that while there are minimum industry efficiency standards for motors per NEMA MG 1,
there are no corresponding industry standards for VFDs yet.
Let's take a look at ASHRAE 90.1/IECC requirements as they directly relate to motors and VFDs. While there
are some differences, both codes typically require some type of control to reduce flow under part-load
conditions for both hydronic and air systems. Here are some examples:
Fan systems serving multiple zones shall be VAV systems (IECC 2012 and 2015).
VAV supply fans that control space temperature by airflow must have the capability to reduce fan motor
demand to 30% power at 50% design air volume and one-third of total design static pressure. This is
applicable to both Standard 90.1 and IECC, but each code has different thresholds for the minimum motor
horsepower where this applies.
Multizone systems that adjust cooling capacity based on space, temperature, at least two stages of fan control
(66% and 40% of full speed), are required for systems larger than 65,000 Btu/h, effective Jan. 1, 2016, under
both ASRHAE 90.1-2013 and IECC 2015.
Pumps in hydronic systems with a combined motor capacity of 10 hp or larger need to automatically vary fluid
flow by not less than 50%. Typical to both Standard 90.1 and IECC.
Under Standard 90.1 (both 2010 and 2013), the individual motor ≥5 hp in hydronic variable-flow systems with
a total system power exceeding 10 hp must also meet the 30% power at 50% flow requirement.
Under Standard 90.1-2010, single-zone VAV with fans 5-hp and greater must be able to reduce their speed to
the larger of 50% or the minimum speed necessary to meet ventilation requirements. Direct-expansion (DX)
units with a capacity of 100,000 Btu/h must be able to reduce speed to two-thirds or the minimum speed
necessary to meet ventilation requirements. Standard 90.1-2013 was revised and makes no distinction
between multizone and single-zone VAV.
Heat-rejection equipment fan control—fan motors ≥7.5 hp shall have the capability to operate at two-thirds full
speed with associated automatic controls (per both Standard 90.1-2010/2013 and IECC 2012/2015).
While this isn't intended to be a comprehensive review of the energy-code requirements, it should be noted
that there's a reoccurring theme to have the ability to reduce flow to 50% and that the power required at half
speed should be no more than 30% of that required at full speed. In fan systems, both codes allow for multiple
means of compliance with these control requirements. These include mechanical or electrical variable speed
drives (VSDs), vane-axial fans with variable-pitch blades, or "other controls and devices."
So, if we're not specifically required to use VFDs, why are we forced to use them? If we look at means of
adjusting flow in VAV systems, we can see that many of the traditional ways to accomplish this don't meet the
30% power consumption at 50% flow requirement. The following is a summary from the ASHRAE 90.1 User's
Manual of various VAV-control methodologies:
Air foil fan with discharge dampers—does not meet efficiency requirement.
Forward curved fan with discharge dampers—does not meet efficiency requirement.
Air foil fan with inlet guide vanes—does not meet efficiency requirement.
Forward curved fan with inlet guide vanes-does not meet efficiency requirement.
Vane-axial fan with variable-pitch blades—may meet the requirement in some circumstances.
Any fan with variable-speed control—generally meets the minimum efficiency requirement.
Actual fan performance will vary depending on multiple factors like static pressure sensor location, fan
selection, etc. But, in general, variable-speed control with VFDs becomes the de facto means of compliance
with this 50% flow/30% power requirement.
While there are multiple variables that can affect overall efficiency in complex HVAC systems, the basic
affinity-law relationships remain valid. It is anticipated that fully modulating control will eventually be required
as the cost of DDC and VFDs continue to fall and the industry agrees on VFD efficiency standards.
Harmonic distortion
With the changes in the energy code, it is inevitable that the use of VFDs will increase. As VFDs start to
represent a disproportionately larger percentage of the electrical-load profile for a facility, the design process
has to consider not just the need to ensure the reliability of the motor and VFD, but also what impact their use
will have on the rest of the facility.
VFDs are nonlinear electrical loads that can create significant electrical harmonic distortion. To change the
speed of a motor, VFDs change the frequency of the ac power wave-form that is supplied to that motor. This is
done by converting 60-Hz ac utility power to dc power, which, in turn, is used to synthesize a new ac power
sine wave. This wave-form can be changed in frequency based on the motor's speed requirements. For this
first ac-to-dc conversion step, VFDs and nonlinear loads generally draw power in short, high-amplitude bursts.
For simple 6-pulse VFD designs, these bursts occur when the rectifier section of the VFD fires at the positive
and negative peaks of the ac sine wave. They don't draw power consistently through the entire sine wave—
only at specific points, thus distorting/notching the wave-form at those peaks.
Nonlinear electrical loads cause "dirty" power. Harmonic content changes the sinusoidal characteristics of ac
power and can result in a wave-form that looks more like a sawtooth profile. Excessive distortion/notching
may result in additional zero crossings in the wave-form, thus affecting electronic equipment that depends on
a consistent 60-Hz electrical-source frequency for proper operation.
We refer to certain "order harmonics" when we refer to the type of wave-form distortion—but what exactly are
they? They are defined by an "integer multiple" of the base frequency of the source. So for example, the 3rd
harmonic in a 60-Hz electrical distribution system would be 180 Hz, the 7th would be 420 Hz, etc.
Certain order harmonics are usually more problematic than others due to the fact that they can arithmetically
reinforce/resonate with each other. The ones that are of greatest concern are commonly referred to as
"triplens." Triplens are odd multiples of the 3rd harmonic (3, 9, 15, 21, etc.). Although predominant in single-
phase nonlinear loads, these aren't an issue with balanced 3-phase loads like motors. However, the 5th, 7th,
11th, and 13th are an issue with balanced 3-phase loads, with the 5th being the greatest concern. The 5th is a
negative-sequence harmonic and, when supplied to a standard induction motor, can produce negative torque
(i.e., slow it down from synchronous speed). Higher-order harmonics beyond these usually aren't as much of a
concern due to their general lower overall magnitude.
How much harmonic distortion is acceptable? IEEE Standard 519: Recommended Practice and Requirements
for Harmonic Control in Electric Power Systems is the industry-accepted standard in this regard. This
standard does not state how to minimize harmonic distortion—it is not a design manual. The latest version,
the 2014 edition, has been significantly abbreviated and deletes most of the specific electrical-design
references and appendixes that were present in the previous version (1992) to emphasize this point. Rather,
the new focus of the standard is to only define the total harmonic distortion (THD) level that is allowable within
an electrical distribution system. The means and methods to achieve these THD limits are at the designer's
discretion. It also notes that the threshold values given are only recommendations and should not be
considered binding in all cases. In fact, the THD requirements have been relaxed in comparison to the
previous version of the standard.
To quantify the harmonic distortion in a sensible manner, you need a consistent point in the electrical
distribution system to measure/calculate it. This point in the electrical distribution system where the harmonic
content is analyzed is called the point of common coupling (PCC). This is typically the low-voltage side of the
utility transformer. Tables 1 and 2 summarize the most pertinent IEEE 519-2014 requirements for voltage and
current distortion.
It is recognized that lower-order harmonics are more difficult to address and also have a greater potential for
power-quality issues. As such, IEEE 519-2014 has new provisions where, if a user can reduce lower-order
harmonics, the threshold values for higher orders of harmonics for current distortion can be increased by a
multiplying factor. Typically, if lower-order harmonics are limited to 25% of the values given in the standard, a
multiplier can be applied to the remaining higher harmonic orders. The multiplier is directly proportional to the
pulse order of the 3-phase rectifier being used. The equation is:
If a 6-pulse VFD was used, the multiplier would be 1.0x. With a 12-pulse VFD,
the multiplier would be 1.41x, with an 18-pulse the multiplier would be 1.73x,
etc. As we examine VFD topologies next, it will make more sense why the
IEEE 519 standard rewards the use of 12- and 18-pulse VFD.
There are four primary VFD design types: 6-, 12-, and 18-pulse, and active front-end. Most mechanical
engineers have a general understanding of what a VFD does, but if push comes to shove, a significant
number can't clearly describe the relative pros and cons for each of these VFD design topologies. Because
the VFDs are often specified and purchased as part of a package with the associated MasterFormat Division
23 HVAC equipment, details on the specifications and performance requirements for those VFDS can often
slip through the cracks.
Cheap
Small
Efficient
Simple.
Line reactors can be added to help mitigate the harmonic distortion. These work by adding an impedance,
which reduces the rate of change in the input, thus helping smooth the pulsing characteristics associated with
harmonics. However, it also slightly reduces overall efficiency and causes voltage drop. So while high-
impedance line reactors are theoretically more effective in mitigating harmonics, a 5%-impedance line reactor
is typically the highest level used.
The 12-pulse VFD is essentially two 6-pulse VFDs grafted together (see Figure 3). This design also uses a
30-degree phase-shift transformer with two outputs. Each output feeds one of the 6-pulse rectifiers, which in
turn are connected to a common dc bus. The VFD draws power 12 times (four times per phase for each of the
three phases) per each complete sine wave cycle. While each 6-pulse rectifier still generates the same
harmonics mentioned previously, what makes this design special is the transformer.
While a 12-pulse VFD goes a long way toward addressing harmonic distortion, there are significant
downsides. Because of the additional components (two rectifiers and a transformer, etc.), the overall cost is
significantly higher and the physical size is much larger. The cost of a 12-pulse VFD will typically be twice that
of a 6-pulse VFD with line reactors. While it is common to have wall-mounted 6-pulse VFDs, most 12-pulse
VFDs are freestanding enclosures. While not necessarily as great a consideration, 12-pulse VFDs are also
slightly less efficient due to transformer losses and additional switching losses associated with the extra
rectifier.
If 12-pulse designs are good, 18-pulse must be better—right? An 18-pulse VFD takes the concept one step
further and uses a 3-output, 20-degree phase-shift transformer to feed three parallel 6-pulse rectifiers (see
Figure 4). This design draws power 18 times (six times per phase for each of the three phases) per each
complete sine wave cycle. This design is also extremely effective in addressing harmonic distortion.
All harmonics below the 17th order are dramatically reduced. Typically, THD will be in the 3% to 6% range.
However, with this type of performance, there are significant increases in cost and complexity. They are
typically only used for larger motor loads where the cost can be justified based on the potential impact that a
large nonlinear load would otherwise have on a facility. The cost for an 18-pulse VFD will typically be 50%
higher than a 12-pulse VFD.
VFDs are "double conversion" devices. They take ac power, convert that in the rectifier section to dc power,
and, finally, the inverter section uses that dc power to resynthesize an ac wave-form (ac to dc to ac). This
basic concept is closely paralleled in another type of equipment, uninterruptible power supplies (UPSs). Many
of the harmonics and power-quality issues discussed in this article regarding VFDs are an even greater issue
in the mission critical UPS marketplace. Standby generators used to provide backup power to those mission
critical facilities were
extremely vulnerable to
harmonic distortion. High
levels of harmonic
distortion could wreak
havoc on a generator's
ability to properly regulate
its output voltage,
therefore jeopardizing the
critical load.
The most current evolution of VFDs reflects this design approach with IGBT-based rectifiers and active
filtering. However, adoption of this new technology still lags far behind the UPS industry. While an active front-
end VFD might be comparable in cost to an 18-pulse VFD, it is dramatically more expensive than a simple 6-
pulse VFD. As such, current applications are typically limited to larger motors where the cost can be justified.
Another limitation of the technology is that IGBTs aren't as robust as traditional SCRs. While UPS
manufacturers are starting to explore the substitution of IGBT in semiconductors with more robust silicon
carbide (SiC) and gallium nitride (GaN), that technology is still in its infancy. It will be a long time before we will
see that technology trickle down to the cost-sensitive VFD marketplace.
Small fractional-horsepower motors (motors below 1 hp) are everywhere—fan coils, fan-powered VAV boxes,
condensing unit fans, induced draft blowers, etc. The 2015 version of the International Energy Conservation
Code (IECC) and ASHRAE Standard 90.1 are also beginning to address smaller fractional-horsepower
motors (smaller than 1 hp) in fan motor applications. While there is a dramatically greater quantity of installed
fractional-horsepower motorsworldwide, larger motors between 1 and 200 hp still use more power overall.
However, with efficiency improvements for larger motors starting to level off, these smaller motors are now
becoming the next target for new efficiency
standards. IECC 2015 and ASHRAE 90.1-2013
now state that fan motors between 1/12 and 1 hp
have to be electronically commutated motors
(ECM) or have a minimum efficiency of 70% at full
speed.
John Yoon is the senior staff electrical engineer for McGuire Engineers. He has more than 20 years of
experience in the design of electrical distribution systems. His project experience covers a broad spectrum,
including high-rise building infrastructure renewal programs, tenant build-outs, mission critical data centers,
laboratories, and industrial facilities. He is a member of the Consulting-Specifying Engineer editorial advisory
board.